HDPE Pipe - A Complete Guide

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Many sectors have historically relied on concrete, metal, and clay for pipe products. However, because of the pressing need to keep production costs down and maintain quality, performance, and efficiency, HDPE pipes have become the preferred material of choice for nearly any project.

Today, HDPE pipes are a necessity as they are built to address modern-day challenges in contemporary development. As demand for water, gas and many more industries continue to soar, the use of HDPE is on the rise and is expected to keep growing.

Technical innovation and development are continually propelling HDPE as a superior material of choice in various applications.

Are Hdpe Pipes Worth It or Are We Biased to Their Use Due to Their Cost Effectiveness?

It wouldn&#;t be much of an article if the answer was yes. The costs are undoubtedly a significant plus, but what good would HDPE products be if they couldn&#;t stand the test of time?

HDPE pipes are a favourite for their &#;green&#; attributes as they can safely convey potable water, wastewater, hazardous waste, chemicals and even compressed gases. We&#;ll look at the how the pipes are manufactured later in the article, but you can read more about HDPE material in its entirety:

To put it all in perspective let&#;s have a look at everything you need to know about HDPE pipes starting with a brief history.    

1. Historic Development of HDPE Pipe

The first ever polyethylene (PE) pipe was produced in . But, the manufacturing costs were extraordinarily high, and chemists had to find new and innovative ways of reducing costs while achieving better yields. After a staggering 20 years, they finally had a breakthrough.

In the &#;s, the first HDPE pipe was created by chemists working at the Phillips Petroleum Co.

HDPE materials were first used to manufacture baby bottles since it was safe and didn&#;t break like glass bottles used at the time.

Here&#;s a short timeline of HDPE&#;s rise to fame:

In the late &#;s, hard-wall HDPE pipe began taking over the functions of metal pipes in gas and oil gathering systems.

In the &#;s PE started replacing iron pipes in nearly all distribution systems. Soon enough, HDPE took over the functions of clay pipes in agricultural drainage frameworks.

In the &#;s, HDPE pipe made headway with advanced diameter width and was corrugated to become a better replacement for metal and concretes in the construction of stormwater culverts.

Today, HDPE is a thermoplastic resin that has continued to evolve throughout the centuries with constant developments in its performance capabilities. They are currently in the fourth generation stage of development. Its uses have diversified to replace glass in bottling and metal making of bails, gas tanks, and drums.

20 years into the future, HDPE pipes are expected to replace cast iron, concrete, and steel in all piping and conduit systems. Which promises a great future in a variety of sectors, including:  

• Natural gas distribution

• Potable (drinking) water

• Plumbing

• Industrial chemicals conveyance

• Oil and gas production

• Underfloor heating

• Mining (slurry and leachates)

• Road heating and cooling

A fairly quick rise to fame and it&#;s not slowing down anytime soon. 

2. How Are HDPE Pipes Manufactured

HDPE, like many other thermoplastic materials, does not possess cross-linked molecular chains and therefore can be melted after application of the right amount of heat. Manufacturing an HDPE Pipe relies heavily on the melting point of PE &#; the temperature at which the plastic gets to an entirely amorphous state (between 120 to 180 °C (248 to 356 °F). 

What Form is HDPE Before it&#;s Melted?

HDPE starts out as pellets, also known as thermoplastic resins. At this point, the first stage of quality control should take place. The raw material quality to be used to manufacture the pipes is the first essential (and necessary) step towards compliance with the specified requirements of a quality finished product.

Most companies use three different types of HDPE pellets which are well mixed before adding it to the hopper &#; plain, recycled and pellets with colorants for UV protection. The mix ratio depends on the specific application of the pipes. If the pipes are going to be buried or used as culverts the need for UV protection is limited, but not excluded as the pipes will still be exposed to UV during installation.

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&#;Depending on the application of the pipe

the quality testing could be very in-depth,

or at least should be if the manufacturer

is worth their salt.&#;

Which means it would use less coloured pellets for productions. Typically, the process starts by feeding the thermoplastic resins into the extrusion machine using a hopper that feeds the pellets onto a rotating screw using gravity. The rotation of the screw moves the plastic along the heated barrel.

As the plastic runs along the channel depth decreases, forcing the plastic through a smaller area. The combination of compression and screw rotation causes friction and rotation, called sheer heating. This heat, with the heat of the barrel, melts the HDPE (at a temperature of about 230 degrees Celcius.) By the time it reaches the end of the line, the material is melted down and hot enough to go through the die.

The hot and melted HDPE is then forced through a die which then causes the solid particles to align in an extruding cavity. After which it can be molded, shaped, and extruded to be formed into a pipe. The hot liquid HDPE is then injected into the pipe mold while applying vacuum pressure for even distribution. An even flow is essential to maintaining the overall integrity of the final product. Any variations in the flow can produce weak areas.

The molten plastic then flows evenly around the mold to form and results in the diameter of the pipe being produced. A built-in cooling system hardens the plastic just enough to set the shape, enabling the pipe to be extracted from the mold. The pipe then passes through a cold shower to completely harden the plastic.

Random pipe samples are then selected for quality inspection. Depending on the application of the pipe the quality testing could be very in-depth, or at least should be if the manufacturer is worth their salt.

3. HDPE Pipe Quality Control

High-density polyethylene (HDPE) pipe is outstanding in many applications thanks to its efficient delivery capabilities. The flexible material can replace traditional pipes and last a long time! Discover the ins and outs of HDPE by reading this guide to the different types of HDPE pipe.

What Is HDPE Pipe?

HDPE pipe is flexible plastic made of thermoplastic high-density polyethylene. A common use is transferring low-temperature fluid and gas. However, chemical and corrosion-resistant pipes often replace aging concrete or steel pipeline mains.

High-density polyethylene is a synthetic polymer that comes from petroleum. The pipe&#;s molecular bond makes it suitable for high-pressure pipelines. Modern uses include carrying hazardous waste, stormwater, and various gases.

Quick History of HDPE Pipe

The first polyethylene (PE) pipe was produced in . Unfortunately, the manufacturing costs were extremely high, and chemists needed to discover innovative ways to reduce costs while achieving better profits. There was a breakthrough after 20 years.

A chemist at Phillips Petroleum Co. created the first HDPE pipe in the s. Manufacturers initially used HDPE material to create baby bottles since it was safe (and didn&#;t break like glass).

During the late s, HDPE pipe took over the functions of metal pipes in gas systems. Throughout the s&#;s, manufacturers integrated these pipes in construction and conduit systems.

Today, HDPE is a thermoplastic resin with optimal performance capabilities. After evolving from its origins of replacing glass baby bottles, the material is common for piping, metal bails, gas tanks, and much more.

Why Is HDPE Pipe Superior?

Because they have excellent characteristics while being cost-effective, HDPE pipe can replace traditional systems. Let&#;s learn why HDPE pipe is superior.

Chemical and Corrosion Resistant

HDPE pipe is resistant to chemicals that could corrode weaker materials. It&#;s important to know that these pipes are chemically inert and don&#;t conduct heat or electricity. They can&#;t create an environment that allows chemical reactions to take place, preventing situations that would decrease performance and longevity.

Temperature Friendly

The pipes are suitable for hot or cold water in various environments. HDPE pipe can handle environmental temperatures ranging from -40 degrees Fahrenheit to 140 degrees Fahrenheit. Additionally, the pipes manage freeze and thaw cycles without sustaining damage.

Cost-Effective

HDPE pipe is less expensive than traditional pipe materials. The pipes are lightweight and easy to handle, which cuts material handling and installation costs. HDPE pipe can replace concrete pipes in sewer systems. Concrete pipes can crack and burst, but HDPE eliminates this possibility, ultimately saving time and money.

Durable

High-density polyethylene is durable and resistant to damage from external loads, pressure surges, or vibrations. The pipes should last from 50 to 100 years because they offer high-impact, chemical, and water resistance. The material doesn&#;t break down like traditional piping, and its lightweight nature adds to a long lifespan.

Lightweight and Flexible

HDPE pipe has solid, straight, or flexible coiled lengths. Their lightweight materials are easy to transport and don&#;t require heavy equipment for installation. Polyethylene pipes have a bend radius of up to 20 times the pipe&#;s diameter, allowing them to conform to unique installation paths without breaking. Additionally, the pipes are not brittle!

Types of HDPE Pipe

The physical and mechanical properties of HDPE pipe include density, yield strength, elongation, hardness, and elastic modulus. Manufacturers classify pipes into pressure grades, known as PN grades. It also includes the standard dimension ratio (SDR), which describes the correlation between the pipe dimension and the thickness of the wall.

Note that the type of HDPE pipe varies depending on the material that the system transfers and its density. Pipes sizes vary in thickness, diameter, and length. Manufacturers can customize pipes for specific applications. There are several different types of HDPE pipe. You can refer to pressure rating charts for an in-depth look at different pipes.

HDPE 80 and HDPE 100 are the main types of HDPE pipe. HDPE 80 pipes transport gas, and HDPE 100 pipes transport liquids like oil and water. HDPE 100 pipes offer higher density for extra durability. They also work under high operating temperatures, making them the most popular!

Pressure Rating Chart

A pressure rating chart lets you classify HDPE pipe systems. Here are common pressures to consider:

• PE 32 &#; low-pressure piping
• PE 40 &#; low-pressure piping
• PE 63 &#; medium-pressure piping
• PE 80 &#; gas pipe for natural gas distribution
• PE 100 &#; high-demand piping applications

HDPE Pipe Applications

Several industries use HDPE pipe for specific purposes. The long-lasting and robust material is ideal for many piping systems. Here are some typical applications:

Industrial

High-density polyethylene is common for domestic sewage systems, sewer effluent control, and water purification in sanitary systems. HDPE pipe transports chemicals and filters water in the petrochemical industry.

Agriculture

HDPE pipe is ideal for irrigation in water supply systems and suction lines. Since the pipes are corrosion and chemical resistant, they don&#;t experience soil corrosion, making them suitable for irrigation and drainage.

Aquaculture

Industries use HDPE pipe for supply lines and floats. The pipes withdraw large volumes of water from various water bodies. They can also serve as cages for planting, seeding, and grading. Some companies use the cages for fish farms.

Mining

The mining industry uses HDPE pipe for surface and underground operations and slurries. The pipes typically transport fluids and chemicals but are also useful for mine dewatering in open mine operations.

Building

Residential and commercial buildings also experience the benefits of HDPE pipe. Builders use the pipes in cold water reticulation systems and to provide ducting for air-conditioning and refrigeration.

Civil Engineering

Companies use HDPE pipe in water mains, service pipes, and sewer reticulation systems. They are also popular conduits for cables in electrical systems.

How Does HDPE Pipe Stick Together?

HDPE pipe and fittings come together by welding or with mechanical fittings. The two types of welding methods are electrofusion welding and butt-welding.

Electrofusion permanently joins individual pipes and fittings or prefabricated sections in tight areas. This method is appropriate for on-site joints.

Butt-welding joins HDPE pipe and fittings into prefabricated sections using heat and pressure. Welders do this without using additional connection fittings.

Besides those two methods, socket welding and extrusion welding can join HDPE pipe. Regardless of the technique, welding pipes prevents weak and leaking joints.

Picking a Good Pipe Supplier

A good HDPE pipe supplier is essential in all applications. The right supplier can ensure high-quality pipes with low maintenance. Companies interested in suppliers should assess service records, cost, reputation, and volume output.

It&#;s best to ask suppliers about their quality control process. Visual inspections, material traceability, and density tests influence performance and longevity. Ultimately, companies need pipes from a hands-on supplier that prioritizes quality assurance.

The Future of HDPE Pipe

You can expect HDPE pipe to replace cast iron, concrete, and steel in most piping and conduit systems. It will improve natural gas distribution, plumbing, underfloor heating, mining, and much more! HDPE pipe won&#;t slow down anytime soon!

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